Medium Power Film Capacitors

Application Notes
INDUCTION HEATING FUNCTION, PRODUCTS
APPLICATIONS DC Filtering
Local thermal treatment, metallic surface hardening, pipe The purpose of the product is to filter the high frequency
welding, tin coating treatment,... ripple coming from the converter in order to avoid rejection
and perturbation on the network.
TPC has developed controlled-self healing range allowing
reliable and competitive solution compare electrolytic
technology.
See calculation example how to replace electrolytic
technology.
Note that on new developments based on IGBT converter,
manufacturer wish to have a main DC filter close to the con-
FUNCTION, PRODUCTS verter and some light filters sprayed on the line.
Products to offer
DC Filtering Main DC Filter FFLC 1120 to 8800μF up to 1200Vdc
The purpose of this filter is to smooth the low frequency Additional FFLI/FFLB 58 to 800μF up to 1900Vdc
ripple coming from the bridge (up to 360 Hz) and to DC Filter FFVE/FFWE 12 to 400μF up to 1900Vdc
filter the high frequency ripple coming from the converter FFG/FFV 5 to 160μF up to 1900Vdc
(15/20 kHz)*.

*Frequency will be lower than capacitor resonance frequency, on

Protection of semi-conductors
request, TPC can propose specific models for high frequency. Overvoltage and clamping due to switching of semi-conductors.
Main criteria are: High rms. current and good behavior Products to offer
against overvoltage are needed. Thyristors and
Products to offer GTO snubbers FPX/FPY 0.5μF to 6μF up to 4600V*
FFG/FFH 5 to 160μF 600 to 1900Vdc IGBT clamping FSB 0.1 to 2.5μF up to 2kVdc
FFVE/FFWE 12 to 400μF 300 to 1900Vdc FFVE 12 to 400μF up to 1.9kVdc
FFVI/FFWI 47 to 275μF 500 to 1100Vdc *higher voltage on request

FFLI/FFLB 58 to 800μF 680 to 1900Vdc

FFLC 1120 to 8800μF 680 to 1200Vdc POWER SUPPLIES AND
RESONANT CONVERTER
Tuning
APPLICATIONS
In order to obtain the requested frequency, a capacitor is
needed to tune with the inductance. The main characteristic Medical X-ray, scanner power supplies
of this capacitor is the reactive power (express in kVar) versus Traction Battery charger
frequency. Industrial All application requesting power supplies
Products to offer
FAI6 10 kHz ≤ F ≤ 100 kHz 1.5 to 60μF
200 to 650Vrms
160 to 1280kVar
FAI1 to 4 100 kHz ≤ F ≤ 500 kHz 110 to 4000nF
300 to 600Vrms
APP NOTES

100 to 300kVar

TRACTION
APPLICATIONS
Speed converter for power for mass transit and/or people
mover system.

53
 Medium Power Film Capacitors
Application Notes

FUNCTION, PRODUCTS Products to offer

FFLI/FFLB 58 to 800μF 680 to 1900Vdc
DC Filtering FFVE/FFWE 12 to 400μF 300 to 1900Vdc
The purpose of this filter is to smooth the low frequency FFVI/FFWI 47 to 275μF 500 to 1100Vdc
ripple coming from the bridge (up to 360 Hz) and to filter the FFB/FFV3 1.5 to 160μF 75 to 1100Vdc
high frequency ripple coming from the converter (15/20 kHz).
High rms. current and good behavior against overvoltage are
needed.
WELDING
Products to offer APPLICATIONS
FFB/FFV3 1.5 to 160μF 75 to 1100Vdc Generate, out of the main supply, through a converter
FFG/FFH 5 to 160μF 600 to 1900Vdc (chopper) and a transformer an overvoltage able to create an
electrical arc.
FFVE/FFWE 12 to 400μF 300 to 1900Vdc
FFVI/FFWI 47 to 275μF 500 to 1100Vdc
FFLI/FFLB 58 to 800μF 680 to 1900Vdc

Tuning
In order to obtain the requested frequency, a capacitor is
needed to tune with the inductance transformer.
The main characteristic of this capacitor is the reactive power
and rms. current.
Products to offer
FAV 80 to 1200nF up to 650Vrms
FAI1 to 4 110 to 4000nF up to 600Vrms

Protection of semi-conductors
Overvoltage and clamping due to switching of semi-conductors.
Products to offer
FUNCTION, PRODUCTS
IGBT clamping FSB 0.1 to 3μF up to 2kVdc DC Filtering
Mos-Fet transistor The purpose of this filter is to smooth the low frequency
protection FSV 10nF to 150nF up to 2kVdc ripple coming from the rectifier (up to 360 Hz) and to filter the
high frequency ripple coming from the converter (15/20 kHz).
SPEED CONVERTER Products to offer
FFVE/FFWE 12 to 400μF 300 to 1900V
APPLICATIONS FFVI/FFWI 47 to 275μF 500 to 1100V
Speed converter for medium power (20 to 100kW) FFB/FFV3 1.5 to 160μF 75 to 1100V
Traction: auxiliary converter for air cooling system, light,...
Industrial: speed variation
ELECTRICAL VEHICLE
FUNCTION, PRODUCTS APPLICATIONS
Battery powered car, electric fork lift truck and hybrid electric
DC Filtering
APP NOTES

vehicle.
The purpose of this product is to filter the high frequency
Due to high rms. current needed through the capacitor,
ripple coming from the converter in order to avoid rejection
metallized controlled self-healing technology will be an
and perturbation on the network.
excellent solution.
Due to IGBT converter, heavy rms. current and very compact
See calculation example on page 58.
product is requested; film technology is able to achieve these
2 targets.

54
Medium Power Film Capacitors
Application Notes

Protection of semi-conductors
Overvoltage and clamping due to switching of semi-conductors.
Products to offer
Snubbers FSB 0.1 to 3μF up to 2kVdc
Clamping FFVE/FFWE 12 to 400μF up to 1.9kVdc

ENERGY STORAGE
APPLICATIONS
Medical: cardiac defibrillator
FUNCTION, PRODUCTS
Industrial and military: laser telemetry, flash lamp
DC Filtering
Between battery and converter, a capacitor is needed. FUNCTION, PRODUCTS
Its main purpose is to filter the ripple coming from the con- DC Filtering
verter, to avoid damaging the battery.
Stored energy is used to generate electrical pulse.
Metallized Film Capacitors are able to fulfill this function using
2 or 3 cases (only electrolytic can not). Products to offer
Products to offer FDV1 5 to 80μF 1000 to 1700V
FDBB 70 to 150μF 1800 to 3000V*
FFVE/FFWE 12 to 400μF 300 to 1900Vdc
FFVI/FFWI 47 to 275μF 500 to 1100Vdc *Specific FDBB can be offered with energy density over more than 1.5J
According to quantity, a custom design could be developed, per cc.
achieving the total function with a single case.
FILM TECHNOLOGY TO REPLACE
ALUMINUM ELECTROLYTIC TECHNOLOGY
WIND MILL The trend in the industrial and traction market for power con-
version is to replace electrolytic capacitors by film technology.
APPLICATIONS This trend is generated by the many advantages that film
Energy power supplied by the wind, new wind mill generation technology offers. Among these advantages, we have:
use electronic converter in order to control power, phase and
*High rms. current capabilities up to 1Arms. per μF
voltage.
*Overvoltage withstanding up to 2 times the rated
voltage
FUNCTION, PRODUCTS
*Handle a reversal voltage
DC Filtering *High peak current capabilities
The purpose of the product is to filter voltage ripple. *No acid inside
TPC has developed controlled self-healing range allowing *Long lifetime
reliable and competitive solution compare electrolytic *No storage problem
technology.
However, this replacement is not necessarily capacitance but
See calculation example how to replace electrolytic for capacitance by application/Function.
technology on pages 57 and 58.
Despite the advantages of film technology, replacement solu-
APP NOTES

Products to offer tions won’t be possible for each application, there will be
FFLC 1120 to 8800μF up to 1200Vdc several approaches to do this.
In order to help the use, we will present some examples
where film gives a major benefit over electrolytic technology.

55
 Medium Power Film Capacitors
Application Notes

1) DC LINK FILTER: HIGH CURRENT 1b) Industrial motor drive, energy supplied
DESIGN & CAPACITANCE VALUE DESIGN from supply network

1a) Energy supplied with batteries

Applications will be: electric car
electric fork lift truck

DC Link Filter

DC link voltage waveform:

U U max

In that case, capacitor will be used as a decoupling capacitor. U

Film capacitor is particularly well adapted for this use,
because main criteria for DC link capacitor will be rms.
current withstanding.
t
It means that DC link capacitor can be designed on rms.
current value. Capacitance value will be defined taken in account that
supply frequency is lower than converter frequency.
If we take an electric car in account as example: To determine needed capacitance, we can use the following
Requirement data: approached equation:
Working voltage: 120Vdc Pload
C=
Ripple voltage allowed: 4Vrms
Uripple
Rms. current: 80 Arms. @ 20kHz Uripple x Umax – x Frectifier
2
Minimum capacitance value will be:
Irms. through capacitor will be (approached expression):
Irms Of course this current doesn’t take in account frequency
C= = 159μF
Uripple x 2 x π x f converter current.

So, it will be easy to find a capacitance value close to these Uripple Pload x π
Irms = x C x 2 x π x Frectifier =
values. 2x 2 Uripple
Umax – 2
Comparison with electrolytic capacitor. 2
If we take in account 20mA per μF for example, in order to
handle 80 Arms, capacitance value minimum would be: So, with this approximation, Irms. through the capacitor will
be depending of the Power of load, Umax and U ripple.
80
APP NOTES

C= = 4000μF
0.02

56
Medium Power Film Capacitors
Application Notes

To illustrate, we will take a concrete example: Lower power will give similar results, and for power up to 10
DC voltage 1000 Volts kwatts, capacitance value becomes so small that film
U ripple 200 volts technology still constitutes the best solution.
Even at 100Hz rectifier frequency, no more than 555μF
100 are needed, supply voltage and ripple still the same than
Dc voltage = 1000V previously.
Capacitance Value (mF)

U ripple = 200V
80 0.5
Dc voltage = 1000V
-P = 1 MW U ripple = 200V
60 -P = 500 kW 0.4

Capacitance Value (mF)

-P = 10 kW
-P = 100 kW
-P = 5 kW
40
0.3 -P = 1 kW

20
0.2

0
0 400 800 1200 1600 2000 0.1
Frequency (Hz)
0
P Irms 100 150 200 250 300 350 400
Frequency (Hz)
1 MW 2468 Arms
500 kW 1234 Arms
100 kW 247 Arms
2) OVERVOLTAGE DESIGN
It becomes necessary to have a zoom on low frequency: We will consider light traction application, like metro,
tramway, electric buses, ...
Dc voltage = 1000V DC link voltage wave form:
Capacitance Value (mF)

U ripple = 200V
40
-P = 1 MW
-P = 500 kW
-P = 100 kW
20
DC Link Filter

0
100 150 200 250 300 350 400
MOTOR
Frequency (Hz)

To compare with electrolytic solution, we will take a current

capability of 20mA per μF for electrolytic capacitors.
First case, power at 1Mwatt: U
Rms. current is 2468 Arms, which would impose minimum Overvoltage
capacitance value of 123.4mF (taking into account
0.02Arms. per μF). Undc
If we look at this value on the curve, we can see that this ⌬V
APP NOTES

capacitance value is needed (the given example for film

technology) for a rectifier frequency lower than 100Hz.
So, with 3 phases, 6 diodes rectifier, frequency will be 300Hz.
We can see on the 1 megawatt curve that capacitance need-
ed is 18.5mF. Film solution will be almost 4 times smaller than
electrolytic solution, with high reliability in addition.
t

57
 Medium Power Film Capacitors
Application Notes

Due to the principle of carrying the power from the catenary This energy calculation will be used for short circuit discharge
to the train, some contact discontinuity appears between between terminal as well. Such discharge will generate a very
pantograph and catenary. high peak current and some ringing that electrolytic could not
When contact is not done, energy come from DC link filter, handle.
with for effect, to decrease the voltage. So, as soon as the
contact is re-established, an overvoltage appears. 3) VOLTAGE RATING
Function of the voltage rating needed, film solution will
V(t) = Undc – ΔV x e-αt x (cos ωt + α sin ωt) become more and more interesting.
ω
If high capacitance value is requested, film solution will be
less competitive. Indeed, if there is no overvoltage, low rms.
with ω = β02 – α2 current, large capacitance value, it will be difficult for film
technology to be competitive below 900 volts.
1
β0 =
LxC LIFETIME CALCULATION
Film technology allows a very long lifetime expectancy,
R
α = depending on voltage load conditions (working voltage) and
2xL hot spot temperature.
Worse case would be ΔV = catenary voltage, because over- For DC filtering, lifetime meets the curves shown in this
voltage could almost reach 2 times the rated voltage. catalog.
So, film capacitor can handle this kind of overvoltage. End of life criteria is a decrease of capacitance value of 2%.
However, this is a theoretical end of life, because capacitor
Comparison with electrolytic technology: can be still used after this point. If application can allow 5%
Electrolytic handle 1.2 DC voltage max: capacitance decrease, lifetime will be widely increased.
So minimum voltage that electrolytic should handle would be: Hot spot temperature will be determined with the following
expression:
2 x 1000V
DC voltage of electrolytic technology: = 1670V
1.2 1
θmaxhotspot = θambient + I2rms x rs + x tgδ x Rth
Cx2x␲ 0
4 capacitors 450 Volts in series would be needed.
Volume occupied for 10mF with electrolytic would be: 26 with: θmaxhotspot: the maximum hot spot temperature
I and Irms. max would be 220Arms.
tgδ0: dielectric losses
With film, volume occupied would be 25 I, and rms. current
capability would be higher than 500Arms. Rth: Thermal resistance
In other hand, link to these overvoltages, peak current Rs: Serial resistance
appear through the capacitor: θhot spot will be 85°C or 105°C function of the
So, we have to calculate the energy generated by this over- application and the technology.
voltage I2t = i 2 (t)dt.
4) CONCLUSION
Cβ02V0 –αt
i(t) = e sin ωt This document gives some ways for the engineer designer to
ω
do their choice. Of course, for each case a complete
C2β04V02 –2αt calculation will have to be done.
i2(t) = e sin2 ωt
ω2 Anyway, if the request is only capacitance value, low voltage,
⬁ ⬁ low rms. Current, no overvoltage, no reversal voltage, no
1 e–2αt C β0 V0 (–α2–ω2 + α2 cos2ωt – αω sin2ωt)
2 4 2

i 2 (t)dt = peak current, film technology certainly won’t be a good

4 αω2 (α2 + ω2)
APP NOTES

0 0 solution.

After few periods, current becomes null, then:

⬁
1 C β0 V0 C2β04V02
2 4 2

i 2 (t)dt = [0] – =1
0 4 α (α2 + ω2) 4 α (α2 + ω2)

1 R
with: β0 = ;α = ; ω = β02 – α2
LxC 2xL

58